Filter connector arrangement having a ferrite barrel with a rectangular bore

ABSTRACT

A filter connector has a ferrite barrel with a rectangular bore therethrough. The configuration of the bore closely matches the substantially rectangular cross sectional configuration of an electrical connector received within the bore. The connector has a pair of wings upstanding from a base thereof. A single gate or a cooperating pair of gates is(are) attached to one or both of the wings. When folded the gate(s) close the bore through the barrel.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of patent application Ser. No.08/317,284, filed Oct. 3, 1994, which is a continuation of patentapplication Ser. No. 08/053,486, filed Apr. 28, 1993, which is acontinuation of patent application Ser. No. 07/968,694, filed Oct. 30,1992.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to a filter connector.

[0004] 2. Description of the Prior Art

[0005] A filter connector is an arrangement that is commonly used invarious applications, such as in electrical detonator circuits, tocontrol electromagnetic interference “EMI” effects. The filter connectorarrangement includes an electrical connector device with filter memberassociated therewith. U.S. Pat. Nos. 3,539,954 (Camire); 4,401,355(Young); 4,647,122 (Kelly); 3,781,723 (Harwood); and 4,020,430 (VanderHeyden) each exemplify a filter connector arrangement.

[0006] In the context of an electrically triggered detonator such asthose utilized to actuate an automobile airbag system, a ferrite barrelis used as the filter member. The ferrite barrel increases theinductance of the firing circuit to provide protection against EMIeffects. An end elevational view of such a filter connector arrangementis shown in FIG. 1. The ferrite barrel F is a generally cylindricalmember having a pair of bores B₁, B₂ therein. Each cylindrical bore hasa respective axis A₁, A₂, extending therethrough. The cross sectionalconfiguration of each bore B₁, B₂ in a plane perpendicular to therespective axis A₁, A₂ thereof is substantially circular. Each bore B₁,B₂ receives an electrical connector C therein. The connectors Cterminate a firing control circuit and provide a receptacle for the pinterminals of the airbag detonator circuit. Suitable for use as theconnector C in FIG. 1 is the connector manufactured by Du Pont ConnectorSystems and sold as Jumbo PV™ connector. U.S. Pat. No. 3,370,265 (Berg)discloses such a connector. This patent is hereby incorporated byreference. This connector C exhibits a generally rectangularconfiguration in a plane perpendicular to its axis.

[0007] Problems of implementation develop when a ferrite barrel F suchas that shown in FIG. 1 is used to surround an electrical connectorhaving a generally rectangular cross section such as that shown by thereference character C. One implementation problem is simply the physicaldifficulty of locating and fitting a rectangular connector C into acylindrical bore B₁, B₂. Tolerances in such an instance become extremelytight and special location features must be developed. Moreover, specialcare must be taken to fix the connector properly within the bore.

[0008] A second problem is generated when the barrel is overmolded, orsurrounded by an encapsulating material. The possibility exists thatinjected plastic overmolding material may enter into the bore B₁, B₂ ofthe ferrite barrel F and interfere with the proper operation of thespring biased contact beam of the connector C.

[0009] Finally, when a connector C with a rectangular configuration isreceived within the cylindrical bore B₁, B₂ of the barrel F optimumelectrical performance is not obtainable.

[0010] In view of the foregoing it is believed advantageous to provide afilter connector arrangement that overcomes the above-mentioneddifficulties.

SUMMARY OF THE INVENTION

[0011] The present invention relate to a filter connector having aferrite barrel with a bore therethrough and an electrical connectortherein. The connector has a substantially rectangular cross sectionalconfiguration in a plane perpendicular to its axis. In accordance withthe present invention the cross sectional configuration of the borethrough the barrel in a plane perpendicular to the axis thereof issubstantially rectangular. The term “rectangular” is to be construed toencompass a connector and a bore that is square in cross sectionalconfiguration.

[0012] Also disclosed is an electrical connector receivable within thebore in the barrel. The connector has a base with a pair of wingsupstanding therefrom. In one embodiment a gate having a substantiallyrectangular configuration is attached to one of the wings. The gate isfoldable with respect to the one wing to close the bore through thebarrel when the connector is received therein. In a modified embodimentof the connector a gate is attached to each of the wings with each gatehaving a substantially rectangular configuration. Each gate is foldablewith respect to the wing to which they are attached to a position whichcloses the bore through the core when the connector is received therein.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The invention will be more fully understood from the followingdetailed description, taken in accordance with the accompanyingdrawings, which form a part of this application and in which:

[0014]FIG. 1 is an end elevational view of a prior art filter connectorusing a ferrite barrel having a cylindrical bore;

[0015]FIG. 2 is an end elevational view of a filter connector inaccordance with the present invention in which the ferrite barrel has arectangular bore;

[0016]FIGS. 3 and 4 are respective sectional views taken along sectionlines 3-3 and section lines 4-4 in FIG. 2 illustrating in plan and sideelevation the structural details of the connector device used in afilter connector arrangement in accordance with the present invention;and

[0017]FIGS. 5 and 6 are sectional views similar to those of FIGS. 3 and4 illustrating in plan and in side elevation a modification to theconnector device of FIGS. 3 and 4.

DETAILED DESCRIPTION OF THE INVENTION

[0018] Throughout this application similar reference numerals refer tosimilar elements in all Figures of the drawings.

[0019]FIG. 2 shows a filter connector arrangement generally indicated bythe reference character 10. The filter connector 10 includes a ferritebarrel 12 having bores 14A, 14B therein. Each bore 14A, 14B has arespective axis 16A, 16B extending therethrough. The filter connector 10further included an electrical connector device 20 received within eachbore 14A, 14B. In accordance with the present invention the bores 14A,14B in the barrel 12 exhibit a substantially rectangular configurationin a plane perpendicular to the respective axis 16A, 16B thereof. Bycasting the ferrite barrel to exhibit bores of rectangular configurationthe physical difficulty of locating and fitting a rectangular connector20 into the bore is eliminated. No special locational features or tighttolerances are required to maintain the connector 20 in the properlocation in the barrel 12. For clarity of illustration in FIGS. 3through 6, a connector 20 is shown in only one of the bores. Moreover,it should be realized that the connector 20 is closely received withinthe bore in which it is disposed, with the spacing surrounding theconnector in FIG. 2 being provided for clarity of illustration. Theclose receipt of the connector 20 within the barrel helps prevent entryof encapsulating material into the bore during overmolding. As usedthroughout this application the term “rectangular” is to be construed toencompass both rectangular and square cross sectional configurations.

[0020]FIGS. 3 and 4 are sectional views through the barrel 12illustrating the connector 20. The Connector 20 is generally similar tothe device disclosed in U.S. Pat. No. 3,370,265 (Berg) which isincorporated by reference herein. The connector 20 has an axis 20A andincludes a base 22 having a socket 24 disposed at the forward endthereof. The socket 24 has a spring biased bowed beam 26 therein. Acrimpable wire ferrule 28 is provided adjacent to the rearward end ofthe base 20.

[0021] The connector 20 is modified over the device shown in theabove-incorporated patent to exhibit a pair of wings 30A, 30B formedalong each lateral edge of the base 22 immediately rearwardly of thesocket 24. The upper portion of each of the upstanding wings 30A, 30B isfolded along a respective fold line 34A, 34B to define resilient fingers36A, 36B at the upper extent of the wings 30A, 30B. As best seen in FIG.4, when the connector 20 is received within the bores 14A, 14B of thebarrel 12 the fingers 36A, 36B acts against the barrel 12 to hold theconnector 20 in place.

[0022] In the embodiment shown in FIGS. 3 and 4, a single gate panel 38is foldably attached to a selected one of the wings 30A, 30B, as thecase may be. The gate panel 38 is substantially rectangular inconfiguration. As shown in FIGS. 3 and 4, when folded along the foldline 40 with the associated wing so as to overlie the base 22, the panel38 serves to close the bore 14A, 14B in which the connector is disposedto prevent the ingress of overmolding material. No further arrangementneed be provided to seal the bore.

[0023] The connector 20 shown in FIGS. 5 and 6 is generally similar tothat described in connection with FIGS. 3 and 4, with the exception thateach of the wings 30A, 30B has a gate panel 38A, 38B defined thereon.The gate panels 38A, 38B each have a substantially rectangularconfiguration. Each gate panel 38A, 38B is foldable with respect to itsassociated wing along a respective fold line 40A, 40B. When in theposition shown in the FIGS. 5 and 6, in which the gate panels 38A, 38Bare folded to overlie the base 22, the panels 38A, 38B cooperate toclose the bore 14 in which the connector 20 is disposed. As a result,the degree of injected plastic overmolding material into the bore 14 isprecluded.

[0024] By providing a bore 14A, 14B within the barrel 12 that isrectangular to conform in cross sectional configuration to the connector20 received therein the electrical performance of the filter isenhanced. simulations of the magnetic performance of a filter connectorusing a ferrite barrel with a cylindrical bore (FIG. 1) and a filterconnector using a ferrite barrel with a rectangular bore (FIG. 2) andhaving, in each instance, the same connector device therein, indicatesthat the inductance presented by the barrel with the rectangular bore isapproximately five times that of the inductance presented by the barrelwith the cylindrical bore, for both the differential current mode andthe common current mode.

[0025] The differential and common mode inductance are summarized asfollows (with ferrite permeability equal to 1000): Barrel BoreDifferential mode Common Mode Configuration Inductance InductanceCylindrical 137 Nano Hy. 61.4 Nano Hy. Rectangular 656 Nano Hy.  302Nano Hy.

[0026] Those skilled in the art, having the benefit of the teachings ofthe present invention as hereinabove set forth, may effect numerousmodifications thereto. Such modifications as are discussed herein andwhich appear to those skilled in the art are to be construed as lyingwithin the scope of the present invention, as defined by the appendedclaims.

I claim:
 1. A filter connector arrangement comprising: a ferrite barrelhaving a bore therein, the bore having an axis therethrough, and anelectrical connector disposed in said bore, said electrical connectorhaving an axis therethrough and a substantially rectangular crosssectional configuration in a plane perpendicular to the axis of theconnector; wherein the improvement comprises: the cross sectionalconfiguration of the bore through the barrel in a plane perpendicular tothe axis thereof is substantially rectangular and said bore accepts saidelectrical connector therein so as to provide improved mating alignmentof said electrical connector with a mating structure within said boreand to provide a substantial increase in both differential and commonmode inductances over a filter connector arrangement comprising saidelectrical connector and a ferrite barrel having a cylindrical bore foraccepting said electrical connector.
 2. A filter connector arrangementcomprising: a ferrite barrel having a substantially rectangular boretherethrough; an overmold material which encapsulates said ferritebarrel; and an electrical connector disposed in said bore, saidelectrical connector having an axis therethrough and a substantiallyrectangular cross sectional configuration in a plane perpendicular tothe axis of the connector, said electrical connector providing improvedmating alignment of said electrical connector with a mating structurewithin said bore, fitting within said ferrite bore so as tosubstantially prevent said overmold material from passing into saidferrite bore around a periphery of said electrical connector, andproviding a substantial increase in both differential and common modeinductances over a filter connector arrangement comprising saidelectrical connector and a ferrite barrel having a cylindrical bore foraccepting said electrical connector.